disclaimer 3 executive summary 4 context of research 4 research

PATH 23: Panel Connections Design Study Final Report

1

PANELIZED WALL SYSTEMS: MAKING THE CONNECTIONS

Prepared for:

U.S. Department of Housing and Urban Development Office of Policy Development and Research

Washington, DC

Prepared by:

Steven Winter Associates, Inc. Norwalk, Connecticut

August 10, 2006

Table of Contents

Acknowledgments 3

Disclaimer 3

Executive Summary 4

Context of Research 4

Research Methodology 5

Performance Standard Criteria 6

Application and Dissemination 18

Appendix A: Panel Connections Comparison Matrix 19

Appendix B: Panel Manufacturer Matrix 68

Panelized Wall Systems: Making the Connections 2

Acknowledgments

The authors would like to recognize the technical advisory group (TAG), which helped contribute to understanding the panel industry and provided review of materials generated in the research. The TAG included Randy Shackelford, Simpson Strong-Tie Company, Inc.; Harold Messenger, Oldcastle Precast; Jim LeRoy, Panel Pros, Inc.; Henry Walthery, Forest Homes, Inc.; Paul Johnson, Duo-Fast; Ron LaMont, Alpine Engineered Products, Inc.; Marc Olden, Mitek Industries; and Mark Daniels, Sika Corporation.

Thanks also to Eric Denny, Oldcastle Precast; Bob Stenzel, Sika Corporation; Lee Zinsle, Senco; John Kurtz, International Staple, Nail and Tool Association; Jeremy Bertrand, NAHB Building Systems Council; and Liza Bowles and Mark Nowak of Newport Partners.

The authors gratefully acknowledge the help and guidance provided by Luis Borray, David Engel, Michael Blanford, and Michael Freedberg of HUD.

Disclaimer

The statements and conclusions contained in this report are those of the authors and do not necessarily reflect the views or policies of the U.S. Department of Housing and Urban Development of the U.S. Government. The authors have made every effort to verify the accuracy and appropriateness of the report’s content. However, no guarantee of the accuracy or completeness of the information or acceptability for compliance with any industry standard or mandatory requirement of any code, law, or regulation is either offered or implied. The products and systems described in the report are included only as examples of some available choices. No endorsement, recommendation, or evaluation of these products or their use is given or implied.


PANELIZED WALL SYSTEMS: MAKING THE CONNECTIONS

Executive Summary

The broad purpose of this research is to understand and document the connection systems of panelized home construction systems currently on the U.S. market with the goal of developing Performance Standard Criteria to help builders and manufacturers. Such criteria can also aid in the development of new panel systems and in the coordination among different types of panel systems.

The Performance Standard Criteria are based on a careful study of existing panel systems. Approximately 30 panelized construction systems were reviewed and 12 were selected for further study. The systems include concrete panels, metal panels, wood structural insulated panels (SIPs), and wood open-wall panels. Performance information on the 12 different systems was collected and then analyzed to develop the criteria. The criteria cite performance standards based on current codes as benchmarks for connections and system performance. Conventional construction practice is considered as the implicit performance baseline at the system level.

The criteria format makes it easy for builders or manufacturers to compare and contrast different system types and the performance of the various elements of the connection systems. A key to maximizing the use of the criteria is to provide builders and panel manufacturers with easy access to the information, through outlets such as the PATH website and trade organizations.

Panel/foundation connection point

Context of Research

HUD has been extensively involved in supporting research and development on building technology innovations, construction systems, products, standards, regulations, and code issues that affect the affordability, safety, and livability of the nation’s housing. As the interrelationships between these topics grow increasingly complex, the continued need to conduct research and demonstrations becomes even more critical.


One of the most important of HUD’s efforts in supporting research and pushing technological innovation has been the PATH program (Partnership for Advancing Technology in Housing). PATH has advanced state-of-the-art practices in the design and construction of affordable housing by accelerating the process of developing and introducing new and innovative technologies and new materials. One technology that has received particular attention is panelized housing construction, which has continued to gain market share, and now accounts for approximately 45 percent of the “building systems” activity in the U.S., according to Automated Builder magazine.

PATH devoted one of its five technology roadmaps (guides to helping the industry make decisions about research and technology development) to “Advanced Panelized Construction.” This research project is in response to activities outlined in the panelization roadmap, to evaluate issues involving the panelization of building components and to develop strategies to better coordinate the use of panelized components currently on the market. A better understanding of the performance of panel connection systems is seen as a way of aiding builders in choosing the most effective panelized components in home construction. Developing “Performance Standard Criteria” for panel connections is one way of assisting builders in comparing different panel systems. Such criteria are also an aid to coordinating the use of different panel systems by builders. They can also serve as standards for new panel systems under development, and the future development of prescriptive connections and proprietary devices for connecting panelized components of differing sizes and materials.

Murus Cam-Lock panel connection system

Research Methodology

Panel System Types

The Performance Standard Criteria for panel connections is based on a careful study of existing panel systems now available in the U.S. Experimental systems were excluded from the study so that the performance criteria are based on panel systems that meet current codes and standards. Approximately 30 panelized systems were reviewed and 12 were selected for further study.


Definition of Performance Measures

The 12 panel systems represent the state-of-practice of connections being used today. The Panel Manufacturer Matrix (Appendix B) categorizes the 12 systems by 4 of the most popular types used by the U.S. homebuilding industry: concrete panels, metal panels, wood structural insulated panels (SIPs), and wood open-wall panels. The 12 systems are distributed among these 4 panel systems types as follows: concrete panels (2 systems); metal panels (3 systems); wood SIPs (4 systems); wood open-wall panels (3 systems).

Performance information collected on the 12 different systems is organized according to four broad categories: General Information; Physical Characteristics; Performance Characteristics; and Connection Interface. Within each of these categories, applicable information is presented for Panel-to-Panel Connections and Panel to Top/Bottom Plate Connections to understand how the connections interface within the panel system itself, and between the panel system and house subsystems such as roofs and foundations. The Panel Connections Comparison Matrix (Appendix A) presents all of the relevant information collected and documented for the 12 panel systems studied, which was then analyzed to develop the Performance Standard Criteria.

Performance Standard Criteria

The 11-page Performance Standard Criteria, which start on the next page, are based on the analysis of the information collected on the 12 panel systems. The Criteria are organized in the same way as the 12 systems of the comparison matrix found in Appendix A: General Information; Physical Characteristics; Performance Characteristics;

Panelized Wall Systems: Making the Connections

and Connection Interface. The criteria are also organized according to the four system types studied: Concrete Panels (which start on page 7); Metal Panels (page 10); Wood SIPs (page13); and Wood Open-Wall Panels (page 16). Where specific metrics are helpful, they have been included throughout the criteria.

There are two levels at which performance is considered: (1) at the individual connection and (2) the effect it has at the system level. For the Criteria, acceptable performance is assumed to be at least as good as the minimum required conventional practice (which is not an engineered system although it implies the presence of acceptable engineering characteristics). For this reason, the Performance Standard Criteria cite performance standards based on current codes as benchmarks for connections and system performance, so as not to place an unfair burden or expectations of higher performance levels on panelized systems. Each of the four panel material types lists Performance Characteristics special to that particular material. For example, the Performance Characteristics for Concrete Panels starts on page 7, in the green-colored section.

Report text continues on page 18

Wausau Homes panel/top plate connection interface 6

Concrete Panels Performance Standard Criteria

General Information Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections Rationale for Criterion

conc Description Investigation of and state-of-practice for two representative concrete panel systems.

conc Panel Types Investigation of and state-of-practice for two representative concrete panel systems.

conc Connection Types Investigation of and state-of-practice for two representative concrete panel systems.

Physical characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections Rationale for Criterion

conc Connection materials Weld plates, bolts, and cementitious grout. A combination of structural steel and cementitious materials: rebar, grout, and bolted steel angles embedded in foundation.

Investigation of and state-of-practice for two representative concrete panel systems.

conc Dimensions and physical characteristics

Weld plates are 8"x4"x3/8"; grout cross-section is approximately 6" wide in the insulation area.

HCA 3" plastic grout tube & #5 rebar; 5"x3-3/8"x4" angles & 1" thick layer of grout.


conc Connection tolerances (min/max)

Connections may yield tolerances up to 1/2". Erection crews must meet manufacturer's recommended tolerances to ensure that connection strength is not compormised.

Embedded bolts must align with angles, requiring precision. More latitude (1/4") is available with rebar in grout tubes than with embedded angles.


conc Connection method at corners Corner connections may be mitred or butt joints, using the same materials as panel-to-panel connections.

Corner connections follow the same method to connect to top and bottom systems.


Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections Rationale for Criterion

conc Conformance with applicable building codes

Typical practice/requirements in existing building codes, design standards, and product approval criteria.

conc Structural strength (min) Code intent.

conc Number of connections (min/max) Panel manufacturer's specifications for project-specific conditions.

Minimum of 2 connection points or more, depending on length and design of panel. Typical top/bottom plate connections pattern is four connections per 12' panel. Spacing may be determined by failure mode in high seismic conditions. Systems using a small number of connectors must have greater reliability (safety margin) at each connection point in case one connector fails. Grout or sealant at connections should be applied continuously.

Solid precast concrete with rebar; precast concrete sandwiching insulation.

Closed-wall concrete panels.

Connections can be continuous or periodic.

Connections are part of a panel system that meets the criteria set forth in the International Residential Code (IRC) and the International Building Code (IBC). Code compliance of connectors may require testing performed in accordance with ASTM standards for strength, fire, mold growth, etc. Custom engineering may be required. Minimum strength of the connector system must be comparable to the strength of the wall panel as a unit. Assembly strength shall be determined in accordance with IRC/IBC or local code requirements (whichever is more stringent) by engineering analysis or structural testing.


conc Connection durability over time Industry practice and materials science findings.

conc Connection fire resistance Code intent.

conc Acoustical separation/insulation at connection

Typical building code sound attenuation criteria and test methods for wall systems.

conc Energy performance at connection Building science, envelope improvement strategies.

conc Moisture/water resistance at connection Building science, envelope improvement strategies.

conc Air infiltration resistance at connection Building science, envelope improvement strategies.

conc Insect and vermin resistance General knowledge, envelope improvement strategies.

Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections Rationale for Criterion

conc Required protection of panel connection system from factory to site

Concrete panel system manufacturer's recommendations.

conc Compatibility with other panel connection systems


conc Compatibility with house subsystems Concrete panel builders' state-of-practice.

conc Ability to accept interior finishes Builders indicate that interior stud wall is the most common finishing application.

Shipment of panels must not compromise integrity or performance of connections or subject connection components to damage, deterioration, corrosion, or decay. Precasting and field bolting must support compatibility, where required by design. With adequate planning, concrete panels should be able to accommodate a variety of systems during the precasting phase. Connection tolerances must be compatible with foundation tolerances. Connections must not interfere with electrical, plumbing, communications, and HVAC systems. With adequate planning, concrete panels should be able to accommodate a variety of systems during the precasting phase. Utilities are not commonly integrated into concrete panels. Connections must not hinder the ability to effectively finish the interior of the panel. Where fasteners are used the connection head must be low-rising so the finish can be applied easily and smoothly. Connections must not corrode or degrade the interior finish.

Panel connections must not create openings for bulk water intrusion. Where grout is not used, builder may apply foam, caulk, or mastic at panel joints as needed to improve performance. Where grout is used, certain joints may require non-shrink grout. Panel connections must not interfere with the builder's ability to use air sealing techniques to achieve superior building envelope performance. Where grout is not used, builder may apply caulk, mastic, or other sealant. Where grout is used, certain joints may require non-shrink grout. Connection materials must not be attractive to pests, and panel connections must be designed such that panels are not subject to insect/vermin infiltration. Adhering to air leakage requirements of IRC (N1102.1.10) will address many infiltration pathways.

Connectors must be at least as durable as the panels themselves. Materials must be protected from forseeable conditions (i.e. steel must be protected from corrosion) that would be encountered either with an exposed connection or with connections hidden within a wall cavity. Certain joints may require non-shrink grout.

Connection method should not reduce the STC rating of the whole panel assembly below that of a conventional wall framed with comparable materials. Continuous insulation at panel connections improves sound attenuation. If insulation is not continuous, acoustical performance at connections should be at least equal to that offered by conventional framing, or that required by code or ordinance (whichever is more stringent). Panels must meet IRC/IECC minimum requirements and should not introduce air movement that may degrade the effective R-value. Thermal shorts should not degrade the performance below that of the effective R-value of a stick-frame wall with framing factors as used to develop the IRC/IECC code requirements. Thermal shorts should not produce cold spots that cause condensation or ghosting.

Connection fire resistance need not necessarily match the resistance of the panels, but connections are part of panel "assembly" which must be tested to meet flame-spread and smoke-development ratings as defined by major building codes.


conc

conc

Connections must not hinder the ability to effectively finish the exterior of the panel. Where fasteners Panel manufacturers' installation andare used the connection head must be low-rising so the finish can be applied easily and smoothly.Ability to accept exterior finishes finishing information.Connections must not corrode or degrade the exterior finish. Irreversible connection methods arePost-construction access must be comparable to that of non-panelized construction.Method of access after assembly comparable to traditional technologies.


Metal Panels Performance Standard Criteria


met Description Investigation of and state-of-practice for three representative metal panel systems.

met Panel Types Investigation of and state-of-practice for three representative metal panel systems.

met Connection Types Panel edges can be formed, or can contain special framing. Connections can be either continuous or intermittent.

Panels must fit into metal tracks at top and bottom. Tracks must be screwed intermittently to both sides of the panel.

Investigation of and state-of-practice for three representative metal panel systems.


met Connection materials Metal framing, formed edges for snap-lock connection, screws, and sealant. Metal tracks, screws, and sealants. Investigation of and state-of-practice for

three representative metal panel systems.

met Dimensions and physical characteristics

Investigation of and state-of-practice for three representative metal panel systems.

met Connection tolerances (min/max)

Connection tolerances typical for screw/mechanical fasteners (1/8-1/4") must be expected. Continuous snap connection must align precisely for mechanism to engage.

Connection tolerances typical for screw/mechanical fasteners (1/8") must be expected.

Manufacturer-described practice; required spacing should depend on system specifics as well as application (e.g., in-fill wall vs. structural load-bearing panel, vs. shear wall).

met Connection method at corners Panels form butt joints at corners. Ends are capped using channels or studs and panels must be fastened with long screws or bolts.

Top and bottom tracks may overlap at corners to complete connection. Manufacturers' installation guidelines.


met Conformance with applicable building codes


met Structural strength Code intent.

met Number of connections (min/max) Panel manufacturer's specifications for project-specific conditions.

Both open- and closed-wall systems.

No standard dimension.

Insulated metal panels combine metal structural support or metal skins (steel or aluminum) with EPS foam.

Minimum strength of the connector system must be comparable to the strength of the wall panel as a unit. Assembly strength shall be determined in accordance with IRC/IBC or local code requirements (whichever is more stringent) by engineering analysis or structural testing. Minimum of 2 connection points, depending on length of panel. Spacing for non-continuous connections is typically 12-24" at panel seams and 12-14" along top and bottom plates, as determined by panel composition, local conditions, and structural properties such as failure mode in high seismic conditions. Systems using a small number of connectors must have greater reliability (safety margin) at each connection point in case one connector fails. Sealants should be applied continuously.

Connections are part of a panel system that meets the criteria set forth in the International Residential Code (IRC) and the International Building Code (IBC). Code compliance of connectors may require testing performed in accordance with ASTM standards for strength, fire, mold growth, etc. Custom engineering may be required.


met Connection durability over time Industry knowledge and materials science findings.

met Connection fire resistance Code intent.

met Acoustical separation/insulation at connection


met Energy performance at connection Based on state-of-industry and best known practices.

met Moisture/water resistance at connection Based on manufacturer information and builder state-of-practice.

met Air infiltration resistance at connection Based on manufacturer information and builder state-of-practice.

met Insect and vermin resistance Based on manufacturer information and builder state-of-practice.

Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections Rationale for Criterion

met Protection of panel connection system from factory to site

Panel system manufacturers' recommendations.

met Compatibility with other panel connection systems

Proprietary connections need not be compatible, but field changes are facilitated if panels support a transition to traditional framing or other panel systems.

Tracks and screws can accommodate other panel systems or traditional metal framing. State of practice.

Connection materials must not be attractive to pests, and panel connections must be designed such that panels are not subject to insect/vermin infiltration. Adhering to air leakage requirements of IRC (N1102.1.10) will address many infiltration pathways.

Panel connections must not interfere with the builder's ability to use air-sealing techniques to achieve superior building envelope performance. An appropriate sealant (caulk, mastic, or other) must be used where recommended by the panel manufacturer, and this sealant must be applied in accordance with both the sealant manufacturer and panel manufacturer's recommendations. Air movement that could result in condensation inside the panel must be prevented.

Connection method should not reduce the STC rating of the whole panel assembly below that of a conventional wall framed with comparable materials. Continuous insulation at panel connections improves sound attenuation. If insulation is not continuous, acoustical performance at connections should be at least equal to that offered by conventional framing, or that required by code or ordinance (whichever is more stringent). Panels must meet IRC/IECC minimum requirements and should not introduce air movement that may degrade the effective R-value. Thermal shorts should not degrade the performance below that of the effective R-value of a stick-frame wall with framing factors as used to develop the IRC/IECC code requirements. Thermal shorts should not produce cold spots that cause condensation or ghosting. Panel connections must not create openings for bulk water intrusion, air movement, or thermal shorts that lead to condensation. An appropriate sealant must be used where recommended by the panel manufacturer, and this sealant must be applied in accordance with both the sealant manufacturer and panel manufacturer's recommendations. Panels and connections must accommodate a weather-resistant barrier required on the exterior by IRC/IBC.

Shipment of panels must not compromise integrity or performance of connections or subject connection components to damage, deterioration, corrosion, or decay. Materials must be protected from moisture.

Connectors must be at least as durable as the panels themselves. Materials must be protected from forseeable conditions (i.e. steel must be protected from corrosion) that would be encountered either with an exposed connection or with connections hidden within a wall cavity. Connection fire resistance need not necessarily match the resistance of the panels, but connections are part of panel "assembly" which must be tested to meet flame-spread and smoke-development ratings as defined by major building codes.


met

met

met

met

Compatibility with house subsystems

Connections must not impede integration of subsystems into panels. Connections must accommodate utitlity chases located within the panels or components recessed into the panel's surface.

Tracks and other connection materials must be compatible with drilling where utilities run vertically through top and bottom connections.

Based on manufacturer data and builder state-of-practice.

Ability to accept interior finishes State of practice.

Ability to accept exterior finishes State of practice.

Method of access after assembly Based on manufacturer data and builder state-of-practice.Sealant may prevent access to interior of wall or assembly after installation.

Connections must not hinder the ability to effectively finish the interior of the panel. Where fasteners are used the connection head must be low-rising so the finish can be applied easily and smoothly. Connections must not corrode or degrade the interior finish. Connections must not hinder the ability to effectively finish the exterior of the panel. Where fasteners are used the connection head must be low-rising so the finish can be applied easily and smoothly. Connections must not corrode or degrade the exterior finish.


Wood SIP Panels Performance Standard Criteria


wsip Description Investigation of and state-of-practice for four representative wood SIPs systems.

wsip Panel Types Investigation of and state-of-practice for four representative wood SIPs systems.

wsip Connection Types Intermittent connections made with splines, screws, or nails, and/or mechanical cam-lock connectors.

Intermittent connections made with dimensional lumber and screws or nails.

Investigation of and state-of-practice for four representative wood SIPs systems.


wsip Connection materials Screws, nails, dimensional lumber, OSB splines, ABS plastic cam-locks, and sealant. Screws, nails, dimensional lumber, sealant. Investigation of and state-of-practice for four

representative wood SIPs systems.

wsip Dimensions and physical characteristics

Splines can be 2x2", 4x3/8", or dimensional lumber size and run the height of the panel. Continuous bead of sealant applied between panels.

Dimensional lumber (2x6 for a 6" panel) used for top and bottom plates. Continuous bead of sealant on both sides of plates.

Investigation of and state-of-practice for four representative wood SIPs systems.

wsip Connection tolerances (min/max) Manufacturer-described practice.

wsip Connection method at corners Panels form butt joints at corners. Ends are capped using studs, and panels must be fastened with long screws or bolts and washers.

Top and/or bottom plates must overlap adjoining panels at corners to complete connection. Manufacturers' installation guidelines.


wsip Conformance with applicable building codes


wsip Structural strength Code intent.

wsip Number of connections (min/max) Panel manufacturer's specifications for project-specific conditions.

Minimum of 2 connection points or more, depending on length of panel. Screw and nail fasteners are typically spaced at 6-12" while specialty cam-lock connectors may be spaced at 24". Spacing is determined by panel composition, local conditions, and structural properties such as failure mode in high-seismic conditions. Top and bottom tracks may be considered part of panel-to-panel connection. Sealants should be applied continuously.

Closed-wall panels.


Connection tolerances typical for screw/mechanical fasteners (1/8") must be expected.

Sheets of OSB sandwiching insulation made of EPS, urethane, or pressed agrifiber.


wsip Connection durability over time

wsip Connection fire resistance

Acoustical separation/insulation atwsip connection

wsip Energy performance at connection

wsip Moisture/water resistance at connection

wsip Air infiltration resistance at connection

wsip Insect and vermin resistance

Connection Interface

Protection of panel connection systemwsip from factory to site

Compatibility with other panelwsip connection systems

Connectors must be at least as durable as the panels themselves. Materials must be protected from forseeable conditions (i.e. steel must be protected from corrosion) such that the panel system as a whole is at least as durable as conventional wood-framing assemblies. Connectors must be appropriate for the type of wood being connected (i.e. treated lumber sill plates require special connectors). Connection fire resistance need not necessarily match the resistance of the panels, but connections are part of panel "assembly" which must be tested to meet flame-spread and smoke-development ratings as defined by major building codes. Connection method should not reduce the STC rating of the whole panel assembly below that of a conventional wall framed with comparable materials. Continuous insulation at panel connections improves sound attenuation. If insulation is not continuous, acoustical performance at connections should be at least equal to that offered by conventional framing, or that required by code or ordinance (whichever is more stringent). Panels must meet IRC/IECC minimum requirements and should not introduce air movement that may degrade the effective R-value. Thermal shorts should not degrade the performance below that of the effective R-value of a stick-frame wall with framing factors as used to develop the IRC/IECC code requirements. Thermal shorts should not produce cold spots that cause condensation or ghosting. Panel connections must not create openings for bulk water intrusion, air movement, or thermal shorts that lead to condensation. An appropriate sealant must be used where recommended by the panel manufacturer, and this sealant must be applied in accordance with both the sealant manufacturer and panel manufacturer's recommendations. Panels and connections must accommodate a weather-resistant barrier required on the exterior by IRC/IBC. Panel connections must not interfere with the builder's ability to use air-sealing techniques to achieve superior building envelope performance. An appropriate sealant (caulk, mastic, or other) must be used where recommended by the panel manufacturer, and this sealant must be applied in accordance with both the sealant manufacturer and panel manufacturer's recommendations. Air movement that could result in condensation inside the panel must be prevented. Connection materials must not be more attractive to pests than conventional building products, and panel connections must be designed such that panels are not subject to insect/vermin infiltration. Adhering to air leakage requirements of IRC (N1102.1.10) will address many infiltration pathways.

Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections


Top and bottom plate connection systems arePanels are customized for a particular spline or interchangeable among most panel types, includingcam-lock but may be field modified to accept other some metal panels and both wood and steel stick-connection systems and traditional wood framing. framing.

Industry knowledge and materials science findings.

Code intent.


Based on state of industry and known best practices.

Manufacturers' data and builder state-of-practice.



Rationale for Criterion

Panel system manufacturers' recommendations.

State of practice.


wsip

wsip

wsip

wsip

Compatibility with house subsystems

Connections must not impede integration of subsystems into panels. Connections must accommodate utitlity chases located within the panels or components recessed into the panel's surface.

Plates and other connection materials must be compatible with drilling where utilities run vertically through top and bottom connections.

Based on manufacturer test results and builder state-of-practice.

Ability to accept interior finishes State of practice.

Ability to accept exterior finishes State of practice.

Method of access after assembly State of practice.

Connections must not hinder the ability to effectively finish the interior of the panel. Where fasteners are used the connection head must be low-rising so the finish can be applied easily and smoothly. Connections must not corrode or degrade the interior finish. Connections must not hinder the ability to effectively finish the exterior of the panel. Where fasteners are used the connection head must be low-rising so the finish can be applied easily and smoothly. Connections must not corrode or degrade the exterior finish.

Sealant may prevent access to interior of wall or assembly after installation.


Wood Panels Performance Standard Criteria

General Information Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections Rationale for Criterion w op

Description Investigation of and state-of-practice for three representative wood panel systems.

w op Panel Types Investigation of and state-of-practice for

three representative wood panel systems. w op

Connection Types Investigation of and state-of-practice for three representative wood panel systems.

Physical characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections Rationale for Criterion w op

Connection materials Screws, nails, dimensional lumber, sealants, optional gaskets. Screws, nails, 2x top plate. Investigation of and state-of-practice for

three representative wood panel systems. w op

Dimensions and physical characteristics 2x4 or 2x6 studs and chords, nails.

Panels have an existing bottom chord that can be attached directly to floor system, and top chord that acts as single top plate.

Investigation of and state-of-practice for three representative wood panel systems.

w op Connection tolerances (min/max) Investigation of and state-of-practice for

three representative wood panel systems.

w op Connection method at corners

Panels form butt joints at corners. Ends are capped using studs, and panels must be fastened with long screws or bolts and washers.

Top and/or bottom tracks must overlap adjoining panels at corners to complete the connection.

Investigation of and state-of-practice for three representative wood panel systems.

Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections Rationale for Criterion w op

Conformance with applicable building codes


w op Structural strength Code intent.

w op Number of connections (min/max) Current industry standards.

w op Connection durability over time Current industry standards.

Manufactured wall panels using conventional wood-framing principles. Panels may arrive on site with exterior sheathing, cladding, and windows and doors installed. Insulation may also be factory applied.

Open wall.

Nails, screws, and bolts are used to connect framing, which consists of dimensional lumber studs and plates.

Connections may yield tolerances up to 1/2" (as with gaskets); or 1/8-1/4" typically expected with mechanical fasteners. Erection crews must meet manufacturer's recommended tolerances to ensure that connection strength is not compormised.

Installer must follow manufacturer's recommendations, which must be designed for performance that is at a minimum equivalent to the performance of analogous connections in conventional construction. Connection durability must be equal to or greater than that of analogous connections in conventional construction. Connectors must be appropriate for the type of wood being connected (i.e. treated lumber sill plates require special connectors).



w op Connection fire resistance Code intent.

w op Acoustical separation/insulation at connection


w op

Energy performance at connection Code intent and builder state-of-practice.

w op

Moisture/water resistance at connection Manufacturers' data and builder state-of-practice.

w op

Air infiltration resistance at connection Manufacturers' data and builder state-of-practice.

w op Insect and vermin resistance Manufacturers' data and builder state-of-

practice.

Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections Rationale for Criterion w op Protection of panel connection system

from factory to site Panel system manufacturers' recommendations.

w op Compatibility with other panel connection systems

May be joined to other framing like wood SIPs or metal framing by using conventional studs and fasteners.

Plates may be used to connect different panel types, or to connect panels to traditional stick framing.

State of practice.

w op Compatibility with house subsystems State of practice.

w op Ability to accept interior finishes State of practice.

w op Ability to accept exterior finishes State of practice.

w op Method of access after assembly State of practice.Connectors must offer access to interior of the wall after assembly that is equal to access offered in a

conventionally framed assembly.


Connection compatibility with house subsystems must be equal to or better than traditional stick framing. Panels may provide a proprietary utilities chase at panel's base, to be covered by trim. Connections must not hinder the ability to effectively finish the interior of the panel. Where fasteners are used the connection head must be low-rising so the finish can be applied easily and smoothly. Connections must not corrode or degrade the interior finish. Connections must not hinder the ability to effectively finish the exterior of the panel. Where fasteners are used the connection head must be low-rising so the finish can be applied easily and smoothly. Connections must not corrode or degrade the exterior finish.

Panel connections must not create openings for bulk water intrusion, air movement, or thermal shorts that lead to condensation. Builder may add sealant at connections for best moisture resistance, following the sealant manufacturer's recommendations for application. Panels and connections must accommodate a weather-resistant barrier required on the exterior by IRC/IBC. Panel connections must not interfere with builders' ability to use air sealing techniques to achieve superior building envelope performance. Builder may apply caulk, mastic, or other sealant according to both the panel manufacturer and sealant manufacturer's recommendations or best practices. Air movement that could result in condensation inside the panel must be prevented. Connection materials must not be more attractive to pests than conventional building products, and panel connections must be designed such that panels are not subject to insect/vermin infiltration. Adhering to air leakage requirements of IRC (N1102.1.10) will address many infiltration pathways.

Connection method must not reduce the STC rating of the whole panel system below that of a conventionally framed wall system using comparable materials. Panels must meet IRC/IECC minimum requirements and should not introduce air movement that may degrade the effective R-value. Thermal shorts should not degrade the performance below that of the effective R-value of a stick-frame wall with framing factors as used to develop the IRC/IECC code requirements. Thermal shorts should not produce cold spots that cause condensation or ghosting.

Connection fire resistance need not necessarily match the resistance of the panels, but connections are part of panel "assembly" which must be tested to meet flame-spread and smoke-development ratings as defined by major building codes.


Conventional construction practice is considered as the implicit performance baseline at a system level, as system-level performance is the key to having a competitive and efficient approach for panelized systems in a market that is defined by site-built system performance. Conformance to applicable building codes should be interpreted to mean that minimum performance for alternative systems should comply with the minimum implied performance of the minimum acceptable conventional (deemed to comply) system.

The criteria are presented in a format that makes it easy for builders or manufacturers to compare and contrast different system types and the performance of the various elements of the connection systems. The criteria are also easily referenced by those developing new panel technology as a standard of performance in the panelized home building industry as it currently operates in the U.S. (thus, it might also be valuable to foreign companies contemplating an entrance into the American market).

To use this tool, the builder can easily compare one system against the other. For example, if a builder has a work force with a very low skill level, it might be decided to select a panel system with as a generous amount of tolerance in making panel connections during site assembly. In reviewing the tolerance levels on a comparative basis, the builder will discover that concrete panel systems offer the greatest dimensional tolerance (1/2”) for connections, compared to metal or wood systems (which are generally in the 1/8” to 1/4” range). The greater level of tolerance for concrete systems might lead the builder to choose such a system.

If a builder is shopping for a panelized system that will allow greater opportunity for on-site inspection by a building official, the

Performance Standard Criteria would indicate that a wood open-wall system would be the better choice over a closed-wall structural insulated panel.

In the case of an architect writing performance specifications, the Performance Standard Criteria can be useful in comparing how different panel systems conform to relevant codes and other performance measures. Language for writing performance specifications can be taken directly from the Performance Standard Criteria, allowing an unbiased comparison of one system to another.

Application and Dissemination

A key to maximizing the use of the Performance Standard Criteria for panel connections is to make them easily available to homebuilders and panel manufacturers. Posting this report on the PATH Website (pathnet.org) is a good starting point in this endeavor. The Criteria might also be posted on the PATH Website pages that deal specifically with panelized construction.

The National Association of Home Builder’s Building Systems Councils (BSC), the trade organization that serves the building systems industries, including panelized housing, has expressed a strong interest in this project and in disseminating its results to its membership, and also in making it available on its own Website, through publications, conferences, and other communications with its membership and its members’ customers. Building Systems magazine and Automated Builder magazine, the two leading trade journals in the field, are also good outlets for the dissemination of the results of this study.


APPENDIX A PANEL CONNECTIONS COMPARISON MATRIX

The Panel Connections Comparison Matrix presents all of the relevant information collected and documented for the 12 panel systems studied, which was then analyzed to develop the Performance Standard Criteria. Performance information collected on these systems is organized according to four broad categories: General Information; Physical Characteristics; Performance Characteristics; and Connection Interface. Within each of these categories, applicable information is presented for Panel-to-Panel Connections and Panel to Top/Bottom Plate Connections to understand how the connections interface within the panel system itself, and between the panel system and house subsystems such as roofs and foundations.


OldCastle Precast - Concrete Panels General Information

Distributor Name OldCastle Precast OldCastle Precast Description Precast concrete panel with rebar (No insulation).

Panel Type Is the panel open-wall or closed-wall?

Solid concrete, most similar to a Closed wall system.

Connection Type Do panel-to-panel and panel-to-top/bottom differ?

Horizontal and vertical connections differ. In panel-to-panel connections, weld plates embedded in each panel are joined together.

On the bottom edge, panels are set over rebar imbedded in grout. Along top edge, panels have pockets (grout tubes) that are filled with grout and rebar, so that the next story of panels (or roof components) can be set over the rebar.

Physical characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections

Connection materials What are the connection materials?

A36 weld plate HCA 3" plastic grout tube and #5 rebar

Dimensions and physical characteristics What are the dimensional characteristics of the connection materials?

8"x4"x3/8" plate HCA 3" plastic grout tube and #5 rebar

Connection tolerances What are the connection tolerances?

1/2" tolerance 1" tolerance

Connection points per panel type How often are the connections made?

2 per edge 4 per panel at top and bottom each

Panel being lowered onto grouted-in-place rebar Panelized constructionPanels erected

Panelized Wal Systems: Making the Connections 20

continuedOldCastle Precast

Panel-to-panel connection (weld plates) Weld plate

Grout tube

Rebar to connect panels at top and bottom

Closeup of embedded plate for welded connectionGrout tube embedded in top edge of panel


continuedOldCastle Precast Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections


What codes does the connection conform to?

AISC and AWS ACI 318

Structural strength What is the structural strength of the connector?

14K shear 16K tension / 15K shear

Number of connections How many connections tie the panel to each other or other building parts?

2 per edge 4 per panel

Connection flexibility Can the connection make angled joints?

Panels can be cast in any shape, and weld plates can make angles. Corners are typically mitered.

Grout tubes and rebar can be installed as needed.

Connection durability over time Is the connection durable or subject to weakening under severe conditions?

Must be protected from corrosion. Must be protected from corrosion.

Connection fire resistance How does the connection perform when subjected to fire?

Must be protected with fire proofing. Must be protected by concrete/grout.

Connection fire resistance and panel performance

How is panel performance compromised if connector is subjected to fire?

Connection will lose strength. Connection will lose strength, but rebar is embedded in the naturally fire-resistant concrete.

Acoustical separation/insulation at connection

How does sound transmit through the panel at the connection?

Overall panel sound insulation is equivalent to a concrete wall. At connections, the builder may apply caulk, mastic or foam to joints after construction to prevent air, sound, and water intrusion.

Overall panel sound insulation is equivalent to a concrete wall. At connections, the builder may apply caulk, mastic or foam to joints after construction to prevent air, sound, and water intrusion.

Energy performance at connection How does the connection perform thermally?

Additional steel contributes to thermal bridging. Caulk, mastic or foam applied to joints post-erection to insulate.

Embedded rebar adds minimal thermal bridging. Caulk, mastic or foam applied post-erection to insulate.

Moisture/water resistance at connection How does the connection resist water and moisture?

Subject to corrosion. Weld plates are located on interior side of wall panels, and caulk is generally applied to exterior of joint to limit water intrusion.

Subject to corrosion. Caulked exterior joint limits water intrusion.

Air infiltration resistance at connection How does the connection resist air infiltration?

Connection provides No appreciable resistance to air infiltration. Joint should be sealed with caulk, mastic or expanding foam.

Connection provides No resistance to air infiltration. Joint should be sealed with caulk, mastic or expanding foam.

Insect and Vermin resistance at connection

How does the connection resist insects and other vermin?

Not affected by insects. Not affected by insects.


continuedOldCastle Precast Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections

Installation of panel connection system in the factory

What components of the connection system are factory applied?

8"x4"x3/8" plate HCA 3" plastic grout tube

Installation of panel connections system on the site

What components of the connection system are site applied?

A36 steel jumper plate or round slug #5 dowel threaded into coupler

Protection of panel connection system from factory to site

How are the factory-applied components protected during transport?

Cast into concrete Cast into concrete

Installation of damaged connections Is installation possible if a connector is damaged?

Yes - through field repairs or redundant connections. Yes - through field repairs or redundant connections.

Ease of installation What is the usual installation process?

Set panels with crane. Weld jumper to plates in adjacent walls.

Tools required for connection What tools are required for the connection to be made?

Welding torch, crane Portable grout mixer, crane

Skill level required for installation What is the approximate skill required to make the connection?

Requires multiple crew members. AWS certified welder. Requires multiple crew members. Certified PCI erector.

Does the connection system support field changes

If changes to the building are made, how does the connection respond?

Depends on the change, but the nature of precast concrete and connections set in concrete limits ability accommodate field changes.

Depends on the change, but the nature of precast concrete and connections set in concrete limits ability accommodate field changes.

Compatibility with other panel connection systems

Is the connection system compatible with other panel and wall systems?

Yes, the panels could tie to other concrete panel systems or be field bolted to steel or other structural members.

Yes, the grout tubes could be used to imbed different types of connectors to attach to different structural systems.

Compatibility with house subsystems Are house subsystems accommodated by the connector?

Connections are spaced widely and do not interfere with house subsystems, although very few systems are actually accommodated in the panel (steel stud wall on interior).

Rebar connections are widely spaced and do not interfere with house subsystems, although utilities are Not commonly run through the panels.

Ease of covering and finishing over connection, Interior

Does the connection system hinder installation of interior finishes?

Interior walls are insulated and framed before finishing, and flat weld plate does not interfere.

Connection is imbedded so does not affect finishing.

Ease of covering and finishing over connection, Exterior

Does the connection system hinder installation of exterior finishes?

Exterior receives no additional finishing other than caulking of joints.

Connection is embedded. Exterior receives no additional finishing other than caulking of joints.

Ease of accessing connection after assembly

Can the connector be accessed after installation?

Yes No

Set panels with crane. Field grouting #5 dowel into plastic tubes.


Dukane Precast - Concrete Panels General Information

Distributor Name Dukane Precast Inc. Dukane Precast Inc. Description Concrete Sandwich. A double wall of precast concrete, with

insulation in the middle and steel trusses girders connecting two sides. The panel is insulated with various types of insulation.


Closed wall


Panels are placed next to each other and grouted from the inside, and caulked from the outside. The connection is continuous.

Connection uses a layer of grout at the panel's top and bottom, plus a continuous steel angle on the interior fastened with bolts embedded in the panels, foundation, etc.



Cementious grout Cementitions grout


A recessed void is filled with grout from the interior side of the panel. Void dimensions are engineered for each panel/connection strength (typically 6").

Recessed void is filled with grout, void dimensions are engineered for each panel/connection strength (typically 6").


The void space can accommodate latitude and the grout easily fills any dimensional discrepancies.

The void space can accommodate latitude and the grout easily fills any dimensional discrepancies. Embedded bolts must align with angles.


Continuous - this is a running connection. Continuous - this is a running connection, although bolts are spaced at intervals.

Detail of panel-to-panel connection Detail of wall-to-slab connection


continuedDukane Precast

Sample wall section

Steel angle connection at ceiling

View of installed panels Grout added to bottom connection


continuedDukane Precast Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Conforms with major building codes. Conforms with major building codes.


Structural strength of connector specifically is not available. Structural strength of connector specifically is not available.


Connection is continuously made, a running connection. Connection is continuously made, a running connection.


Connection can make angled joints. Panel may need additional support/bracing but can make angled connections


The connection of the panels is made in the interior of the wall system by pumping cementious grout into the cavity created when two walls join, the grout fills the cavity and around the wall panel's reinforcement. Grout is a durable material.

The connection of the panels is made in the interior of the wall system by pumping cementious grout into the cavity created when two walls join, the grout fills the cavity and around the wall panel's reinforcement.


Concrete and cementious grout are fire resistant, but at high temperatures the steel reinforcement in the panel fails.

Concrete and cementious grout are fire resistant, but at high temperatures the steel reinforcement in the panel fails.



Connector performs as well as panel in fire. Steel is inclosed in concrete.



Performs well acoustically. Performs well acoustically.


Grout has thermal bridging like any concrete product, the panel is insulated at its core, the connection is un-insulated.

Grout has thermal bridging like any concrete product, the panel is insulated at its core, the connection is un-insulated.


Continuous connection will not likely be susceptible to water infiltration.

Continuous connection will not likely be susceptible to water infiltration.


Grouting fills the cavity fully and because it is a liquid fills any manufacturing defects which might have caused voids to form.

Grouting fills the cavity fully and because it is a liquid fills any manufacturing defects which might have caused voids to form.



Grout forms a barrier that insects and vermin can not penetrate. Grout forms a barrier that insects and vermin can not penetrate.


continuedDukane Precast Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



The void or recesses for the grout, and the exposed reinforcement.

The void or recesses for the grout, and the exposed reinforcement.



Cementious grout Cementious grout



Because the panel connections made into the interior of the panel it is inherently protected, but because the connection is made with cementious grout any defects or damaged areas are inherently fixed during installation.

Because the panel connections made into the interior of the panel it is inherently protected, but because the connection is made with cementious grout any defects or damaged areas are inherently fixed during installation.


Yes, the grout should fill any void and is stronger than the concrete in the panel.

Yes, the grout should fill any void and is stronger than the concrete in the panel.


The panels are set into place using a crane and braced. After all the panels are set and braced, concrete grout is pumped into the voids. After the concrete sets up the bracing can be removed.

The panels are set into place using a crane and braced. After all the panels are set and braced, concrete grout is pumped into the voids and steel angles are secured. After the concrete sets up the bracing can be removed.


Crane to set panels, concrete mixer and pump to pump grout into voids.

Crane to set panels, concrete mixer and pump to pump grout into voids.


Crews must be trained to set panels and to install grout. Crews must be trained to set panels and to install grout.



While the grout itself when liquid is a flexible material, panels are difficult to alter if construction plans change. The concrete and the grout (once hardened) are both very difficult to cut and therefore field adaptability is extremely limited.

While the grout itself when liquid is a flexible material, panels are difficult to alter if construction plans change. The concrete and the grout (once hardened) are both very difficult to cut and therefore field adaptability is extremely limited.



While not inherently proprietary, the system limits possible successive connections that can feasibly be added -- all connections must be cast during the factory production.

While not inherently proprietary, the system limits possible successive connections that can feasibly be added -- all connections must be cast during the factory production.


Utility accommodations must be cast at the factory and require careful coordination. Once grout is poured, changes to utilities through the connection area will Not be practical.

Utility accommodations must be cast at the factory and require careful coordination. Once grout is poured, changes to utilities through the connection area will Not be practical.



Connection is recessed in the wall. Connection is recessed in the wall.



Connection is recessed in the wall. Connection is recessed in the wall.



No access No access


ThermaSteel - Metal Core Panels General Information

Distributor Name ThermaSteel ThermaSteel Description Steel Frame/Foam. A panel with a core of EPS framed with 24

gauge, G-90 galvanizing steel channels imbedded in the foam on either side of the panel for support.

In business for 30 years Now. Have been used in all 50 states and many countries around the world. Manufacturing plants in Virginia, Alaska, and Russia.


Open Wall


Shiplap joints are molded into the panel, and panels are connected to each other via many connection points, 16" o.c. Screws are driven through the joint to connect the panels.

Connects to foundation either sitting over wood 2x plate, or sitting in steel track. This analysis will focus on the steel track.



Panels are pre-shaped to form shiplap joint, and connection is made using caulk and screws.

Metal track, screws.


Interior panel spline: Shiplap joints tie into top plate and bottom plate, #8 self taping screws every 12".

#8 self tapping screws every 12-14" o.c. to tie system into top and bottom plate.


1/4" Track must be level; panels should not be shimmed.


Connect to next panel sequence, and to sheathing material every 12"-14" o.c.

Connections made to top and bottom plates 12-14" o.c.

Sample wall panel Setting Panel into Bottom Track


ThermaSteel continued

continuedThermaSteel

InstallationDetail of connection at bottom track (same at top)

Panel-to-Panel Connection

View of Installed Panels


continuedThermaSteel Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Panels conform to all codes including Dade County, ICCES #4216, BOCA, SBCCI, and HUD. Has also passed hurricane projectile test (11 studs on exterior side of hurricane panels).

Panels conform to all codes including Dade County, ICCES #4216, BOCA, SBCCI, and HUD. Has also passed hurricane projectile test (11 studs on exterior side of hurricane panels).


N/A N/A


9 panel-to-panel connections - 12" o.c. along shiplap. 16 connections for each panel-to-track connection (assuming 16" o.c.). 2 screws at each stud.


Panels can make angled joints but would use some sort of plates or channels to secure, rather than the shiplap. Yes, track is easily adaptable.


Screws and metal channels are durable. Screws and metal channels are durable.


Meets 1-hour fire rating but teel is Not fire resistant, so an additional layer of protection is needed.

Meets 1-hour fire rating but teel is Not fire resistant, so an additional layer of protection is needed.



Flame spread of panel is 5+++ for 4" thick (see UL flame spread test results). Connection will fail during a fire at the same rate a the rest of the panel.

Metal channel will fail during fire.



Steel is primarily on the surface of the EPS foam, so sound does not transmit

Minimal sound transmission.


Metal studs do not go through the panel, so thermal bridging is eliminated. Screws could potentially conduct heat and cold but are not expected to compromise thermal performance of panel.

The metal tracks at the top and bottom of the panel will be the weak point thermally, as the steel will transmit temperatures between interior and exterior.


Poor if water accumulates on metal components and rusts. Relies on finishes for water protection.

Poor if water accumulates on metal components and rusts. Relies on finishes for water protection.


Possible at joint if no sealant is used, but foam shiplap edge makes air travel difficult.

Possible at joint if no sealant is used, but shape of metal track makes air travel difficult.



Steel resists insects but they can easily bore through foam. Steel resists insects but they can easily bore through foam.


continuedThermaSteel Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Shiplap edges are formed in the factory. Tracks are manufactured in the plant and shipped with the panels.



All screws are installed onsite. All screws are applied on site including panel-to-panel, panel-to-track, and track-to-sill plate.



No special protection. Metal tracks can be bent if stepped on but can be either reshaped in the field, or replacement materials are readily available.


Screw should be replaced if it is damaged. If shiplap edges or metal studs become damaged, they could be field repaired using metal framing.

Metal tracks can be either reshaped in the field, or replacement materials are readily available.


Panel is placed into bottom track, aligned next to subsequent panel, and locked together by top plate and interior screws at connections.

Panel is placed into bottom track, aligned next to subsequent panel, and locked together by top plate and interior screws at connections.


Drill, screws Drill, screws


Low skill level sufficient. Low skill level sufficient.



Yes, because the construction is similar to SIPs in detail and similar to steel framing it is easy to adapt panels and connections system in the field.

Yes, because the construction is similar to SIPs in detail and similar to steel framing it is easy to adapt panels and connections system in the field.



The panels could be used in conjunction with other panel types, but the shiplap joint would not transfer to the next panel. A flush ThermaSteel panel could be installed next to another flush panel

Because either wood or metal tracks/plates can be used, the panels can tie into wood framing, wood SIPs, metal framing or metal SIPs.


Chases are included. Although screws enter into the center of the panel, the connectors are spaced 12" or more so the connection does not interfere with utilities.

No penetration expected through top and bottom connections.



Drywall is installaed directly over the panel. Unlike some other panel sytems, finishing crews must be sure to hit the metal studs in the panel to secure cladding.

No hindrance for interior finishes.



Unlike some other panel sytems, finishing crews must be sure to hit the metal studs in the panel to secure cladding.

No hindrance for exterior finishes.



Screws can be removed but caulking at foam shiplap joint may cause panels to be damaged if torn apart.

Screws can be removed from tracks but sealant may make it difficult to remove panels intact.


Acsys - Metal Core Panels General Information

Distributor Name Acsys Panel System Acsys Panel System Description Steel Frame/Foam. An insulated steel-core wall panel made of

16-20 gauge galvanized corrugated structural core welded to a top and bottom 18 gauge galvanized steel track. Steel tracks are embedded in expanded polystyrene skin using a specialized molding process.

Acsys is the residential line but is identical to Koreteck, the version more widely used in light commercial construction. System is often used by Wendy's and Taco Bell and works particularly well with a stucco finish. Systems is most often used as in curtainwall (not structural) applications.


Hybrid - Neither a skin nor a stud panel, uses a perforated steel core with foam on either side.


Segments of steel core overlap like a shiplap joint and are screwed together. Corner and angled connections are made using formed metal channels screwed to the steel core.

Panels are fitted with factory-installed metal channels at top and bottom, which in turn fit into steel bottom tracks and top caps and are fastened with screws.



The panels are connected together using #14 x 3/4" galvanized self-drilling hex head screws. Zee channels are used at corners, attached 12" o.c.

18-guage galvanized steel top and bottom channels are integral to panel. Framing fits into a track over continuous bead of sealant. panels screwed to track.


#14 self tapping screws every 24" o.c. panel to panel through shiplap joints. Shiplap = 1.5"; 3/4" to centerline.

#14 1/4" x 3/4" self-drilling screws used min. 12" o.c., except where structural member must fasten to the core - then use screws 2-1/2" long. Shaped channels (zee, etc.) used to stack panels and at intersections.


Accommodates about 1/8" of "give". Accommodates about 1/8" of "give".


24" o.c. minimum, along panel seams, and 12" o.c. at corners. Minimum of 12" o.c.

Panels being tipped up into bottom track Panel is screwed into bottom track


Acsys continued View along top edge

Corrugated steel core

Screws on exterior

Panels packed and wrapped for shipping


Acsys continued

Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



ICC for building materials; Underwriters Laboratories for fire tests; ASTM for steel, mold growth, and water vapor transmission.

ICC for building materials; Underwriters Laboratories for fire tests; ASTM for steel, mold growth, and water vapor transmission.


N/A N/A


Fasteners are all screws, tied to steel core of panel or to shaped channels - track, corner, zee.

Fasteners are all screws, tied to steel core of panel or to shaped channels - track, corner, zee.


Track and panels can be easily adaptable to all angles. Track and panels can be easily adaptable to all angles.


Metal screws and channels are durable. Metal screws and channels are durable.


Metal fasteners will eventually fail in a fire and must be protected with finishes.

Metal tracks and fasteners will eventually fail in a fire and must be protected with finishes.



Panels and connections meet fire requirements. Greater portion of metal at connections than in panels may cause connections to fail first in a fire - not tested specifically.

Panels and connections meet fire requirements. Greater portion of metal at connections than in panels may cause connections to fail first in a fire - not tested specifically.



Insulates sound well. Connections have no significant increase in sound transmission.

Metal track transmits sound but top and bottom tracks are blocked by min. 1" thick EPS block.


Thermal bridging minimal - 3/4" long connectors 24" o.c. imbedded in the foam

EPS filler block added after connections are complete.


Galvanized steel resists rust. EPS resists mold. Connectors are galvanized also. Sealant helps stop moisture transmission.

Galvanized steel resists rust. EPS resists mold. Connectors are galvanized also. Sealant helps stop moisture transmission.


Connections are imbedded in foam. Sealant and EPS blocks limit air infiltration.



Foam could be susceptible to vermin but should Not be appealing. Screws not affected.

Foam could be susceptible to vermin but should Not be appealing. Screws not affected.


Acsys continued

Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Panel connection is inherently installed in the fabrication of the panel system.

Track mounted onsite.



Screws and channels (where needed) added onsite. Screws, sealant and channels (where needed) added onsite.



Wrapped in plastic for moisture protection. Only susceptible to dents in foam, which don't compromise performance much.

Wrapped in plastic for moisture protection. Only susceptible to dents in foam, which don't compromise performance much.


Yes, metal can likely be straightened. Unlikely to damage beyond repair.

Yes, metal can likely be straightened. Unlikely to damage beyond repair.


Easy to set and tie panels together. Training takes about 4 hours.

Mount track, add sealant, place panel, fasten to bottom, fasten shiplap.


Drill, screws Drill, screws


Foam is marked to indicate where to drill (high and low sides of corrugation). One experienced crew member (familiar with order and layout) can direct crew with low skill level.

Foam is marked to indicate where to drill (high and low sides of corrugation). One experienced crew member (familiar with order and layout) can direct crew with low skill level.



Easy to modify plan designs, panels can be modified on site to some degree but may need to special order channels, which can not easily be site fabricated.

Yes: Easy to modify plan designs, panels can be modified on site to some degree but may need to special order channels, which can not easily be site fabricated.



Metal channels could potentially connect to other metal-based panel connection systems. Can connect with metal stud wall.

Metal channels could potentially connect to other metal-based panel connection systems. Can connect with metal stud wall.


Yes - because foam is on the outside, utilities can be imbedded using a hot knife without interacting with the connection.

Yes - because foam is on the outside, utilities can be imbedded using a hot knife without interacting with the connection.



Requires longer drywall screws. Requires longer drywall screws.



Designed to work with stucco finish. Use of siding would require additional drainage and support measures.

Designed to work with stucco finish. Use of siding would require additional drainage and support measures.



Difficult to locate screws imbedded in foam. Sealant and added blocks of EPS interfere.


SIPbLOC - Metal SIP Panels General Information

Distributor Name SIPbLOC SIPbLOC Description SIP- Steel/Metal Sheet/Foam Core - made of expanded

polystyrene (EPS) foam insulation sandwiched between two structural steel skins. Finished with embossed aluminum coil, or embossed galvanized steel composite, in stucco, cedar wood grain, or smooth patterns.Snap-N-Lock system used to connect panels.


Closed wall


Fits over bottom plate. Connected at many points.



Metal sips rest in a track anchored into the foundation, and metal edges are formed with a special lip on vertical edges so panels next to each other snap together.


Snapping joints are manufactured into each panel, which uses EPS foam and skins of either aluminum or steel.

A steel C-channel is used to anchor the wall system to the foundation or slab, and another C-channel acts as the top cap. Screws connect panel skins to the channels.


Horizontal latitude is minimal because snap connection pulls panels tightly together.

The snap connection would allow for some vertical latitude.


Continuous snap connection. Connections are made on each side of the panel with screws.

Panels snap together with specially formed edges

Cross section of metal SIP panel Stack of SIPbLOC panels


Panel edge Panels installed

Panels with metal firring Metal firring for easier electrical installation


continuedSIPbLOC Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



International Building Code, California Building Code, Florida Building Code.

International Building Code, California Building Code, Florida Building Code


Structural strength is available for the panel system as a whole.


One continuous connection is made between panels. Screws spacing is dictated by loads and conditions, 6"-12" o.c.


Track and panels can be easily adaptable to all angles. Track and panels can be easily adaptable to all angles.


Track is easy to install, and panel to panel connections are embedded into each other.

Track is easy to install, and panel to panel connections are embedded into each other.


Steel is not fire resistant, so an additional layer of protection is needed. Left unprotected, connection will fail during a fire.

Test samples meet UBC 26-3.



Metal warps, yet stays intact. The snap connection is likely to perform the same as the wall.

Metal warps, yet stays intact.



Foam meets foam inside skins for continuous insulation. Sound transmission is minimal.


Foam meets foam for continuous insulation. Thin metal track is only conductor.


Entire panel is formed with moisture resistance. Entire panel is formed with moisture resistance.


Panel to panel connections snap together and sealed with sealant.

Sealant at bottom track helps prevent air infiltration, and track shape limits airflow.



Panel connections are tight and resist insect infiltration. Panel connections are tight and resist insect infiltration.

Structural strength is available for the panel system as a whole.


continuedSIPbLOC Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Panel connection is inherently installed in the fabrication of the panel system.

Metal tracks are shipped with panels.



The sealant is applied on site. Tracks, screws and sealant are site-applied.



Plastic film protects the metal finish. Panels are covered on the shipping truck.

Metal channels are galvanized and are Not protected.


Installation is difficult and can be impossible if damaged. Metal track can be repaired or replaced with common metal framing materials.


Installation process is straight forward and can be performed by a lower skill level.

Installation process is straight forward and can be performed by a lower skill level.


Drill, screws. Caulking gun, drill, screws.


Low Low



Easy to modify plan designs, might be difficult to modify panel size/shape.

Easy to modify plans, more difficult to move panels but it is easy to cut in windows, doors, and walls.



Can be used in conjunction with other wall systems with preplanning.

Can be used in conjunction with other wall systems with preplanning.


House wiring can run uninterrupted through the foam at connection points.

House wiring can be accomodated by prefabricated wiring hole, but builderd often fir out interior walls to house electrical.



The connection system does not interfere or inhibit Interior or Exterior finishes.








Theoretically possible to disassemble, except for sealant. Theoretically possible to disassemble, except for sealant.


Insulspan - Wood SIP Panels General Information

Distributor Name Insulspan Insulspan Description Wood SIP. Panels are made of an expanded polystyrene (EPS)

core bonded between two outer layers of rugged oriented strand board (OSB). Several typical SIP connections are possible inculding 2x lumber spline, but analysis focuses on double OSB surface spline.


Closed


Strips of OSB are used to spline two adjacent panels together. Panels fit over a 2x bottom plate and are nailed at many points. Top plates overlap adjacent panels.



Many different details are available; however, this analysis focuses on OSB splines fitting into grooves just behind the panel sheathing. Sealant, nails, and screws are used to complete the connection. 2x lumber is used for panel ends at corners.

Foam is recessed to accommodate top and bottom plates made of dimensional lumber. Connect with nails/screws and sealant. Trusses/joists rest in hangers nailed to OSB.


Plywood splines are 7/16" x 3" and run the height of the panel. Two are used at each panel-to-panel connection, fastened with 1-5/8" drywall screws or nails. At corners or where panels meet dimensional lumber, use 8" spikes or screws for a 6" panel. Foam keyway is 3/4" x 3/4".

For 6" panels, used 2x6 lumber for top and bottom plates.


There is some measure of latitude that can be taken up by the panels (perhaps 1/8") but any gaps must be filled with foam sealant. Gaps larger than 1/8" require special IFS sealant.

There is some amount of latitude.


Nailing pattern is typically 6" o.c. with 1-5/8" drywall screws or nails on either side of the seam between panels. Expanding foam sealant is applied to a central channel through holes spaced 12-18" to create a continuous bond. At T-intersections or corners, use use long (8" for 6" panel) screws w/ 2" dia. washers to drive through panel into a 2x end plate in the intersecting wall.

2x sill plate is nailed or bolted to foundation or trusses (pattern varies, 16" to 4' o.c.) and OSB panel skins are nailed to the sill and top plates at 6" o.c. on both sides. Roof panels are screwed to top plate at 8" o.c. w/ 2" dia. washers.


Insulspan continued

Sketch of double OSB spline at panel-to-panel connection Panel-to-foundation

Insulspan SIP Installation Architectural detail of panel-to-panel connection


Insulspan continued




Panels conform to BOCA, ICBO, SBCCI, and ICC. Tested for structural properties including racking load, surface burning characteristics, fire resistance, compressive strength tests, sound transmission, water vapor transmission.

Same as panel-to-panel.


Maximum allowable racking load for stapled surface splines is 208 PLF; for nailed 2x wood splines it is 385 PLF.



Top and bottom plates, OSB splines, nails and sealant. Nailing pattern is as described above.

Top and bottom plates connect to foundation/roof assemblies. Hangers for trusses/joists can be nailed directly to panel skins.


Panels can be easily adaptable to all angles, but 2x lumber may be needed to make these splines.

Top and bottom plates can make a variety of angles.


OSB splines perform well in most conditions but could potentially weaken under intense racking, steam, fire, etc.

Durability of connections at top and bottom is compatible to that of stick-frame construction.


Test results from a National Evaluation Report show that OSB or plywood surface splines may be used "when spline studs [2x] are Not required for structural capacity or to meet fire resistive assembly details."

Dimensional lumber is susceptible to fire but connection is comparable to stick-frame construction.



Once connection fails, whole wall failure will follow close behind. spline connections.



Only 7/8" less insulating foam occurs at panel-to-panel connections.

Acoustical performance equals that of 2x lumber.


Whole-wall R-value of 6-1/2" wall is R 23.3 with with surface splines; R 22.3 with a solid 2x6 spline.

Thermal performance equals that of 2x lumber.


Expanding sealant helps limit moisture infiltration. Panel Seal Tape can be used to add another layer of protection. Inert foam insulation is not affected by moisture.

Sealant on both sides of bottom plate helps obstruct water path. Panel Seal Tape recommended at all panel-to-roof connections.


Expanding sealant in central keyway helps limit air infiltration. Panel Seal Tape can be used to add another layer of protection. Inert foam insulation is not affected by moisture. Surface splines block direct path from interior to exterior.

Sealant on both sides of bottom plate helps block air. Panel Seal Tape recommended at all panel-to-roof connections.



OSB can be treated with borate. EPS is penetrable but not particularly attractive to pests.

Similar to traditional stick frame construction.

Connections at top and bottom are less likely to fail than the


Insulspan continued




Foam is routed to fit splines and foam keyway. Splines cut to length.

Foam is routed to accommodate top/bottom plates.



Surface splines, expanding foam sealant, nails/fasteners. Plates, hangers (if needed), sealant, nails/fasteners.



Occassionally OSB panel edges can get damaged during shipping - makes installation more difficult, not impossible. Panels and connectors must be kept dry.

None.


Splintered edges may be OK but broken surface splines need to be replaced - easy to cut more onsite.

If damaged, plates are easily replaced onsite and foam can be hot-scooped out to accommodate connections.


Attach bottom plate to foundation or floor, set panel over plate and nail. Pound in splines, set next panel, and screw/nail together. Top plate overlaps. Drill holes and spray in foam.



Hammer, foam sealant, nails, long screws, washers. Hammer, foam sealant, nails, long screws, washers, Panel Seal Tape.


Low Low



Yes: Panels can be modified and new connection points added but cutting panels and molding foam can be messy. New splines can easily be created onsite.




Product should interface with any other wood SIP system or wood framed construction.



Surface splines allow utilities to run continuously through the center of the panels.

Plates can be drilled out to accommodate utilities.



Very easy, no need to find studs and surface is very even. N/A



Very easy, no need to find studs and surface is very even. N/A



SIPs can be modified or removed after they are installed by cutting the panels, but sealants and frequent nails/fasteners will make getting panels apart intact difficult.

N/A


Precision Panel - Wood SIP Panels General Information

Distributor Name Precision Panel Precision Panel Description Wood SIP. Panel are made of an expanded polystyrene (EPS)

core bonded between two outer layers of rugged oriented strand board (OSB). Several typical SIP connections are possible inculding 2x lumber spline, but analysis focuses on 2x4 lumber spline.


Closed


Panels fit over bottom 2x plate. 2x studs run vertically between adjacent panels. Nails are used to secure panel skins to plates and stud/spline.



Many different details are available; however, this analysis focuses on 2x lumber splines fitting into grooves just behind the panel sheathing. Sealant, nails, and screws are used to complete the connection. Expanding foam sealant completes the connection.

Foam is recessed to accommodate top and bottom plates made of dimensional lumber. Connect with nails/screws and sealant. Trusses/joists rest in hangers nailed to OSB.


2x splines are typical studs and run the height of the panel. One is used at each panel-to-panel connection, fastened with 8d nails.

For 6" panels, use 2x6 lumber for top and bottom plates.


There is some measure of latitude that can be taken up by the panels (perhaps 1/8") but any gaps must be filled with foam sealant.

There is some amount of latitude.


Nailing pattern is typically 6" o.c. on either side of the seam between panels. Expanding foam sealant is applied down the middle of the foam core before panels are placed against spline.

2x sill plate is nailed or bolted to foundation or trusses (pattern varies, 16" to 48" o.c.) and OSB panel skins are nailed to the sill and top plates at 6" o.c. on both sides. Roof panels are screwed to top plate at 8" o.c. with 2" dia. washers.

Panels screwed together in field


continuedPrecision

Details of 2x wood spline connection for panel-to-panel


continuedPrecision Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Panels conform to BOCA, ICBO, SBCCI, and ICC. Tested for structural properties including racking load, surface burning characteristics, fire resistance, compressive strength tests, sound transmission, water vapor transmission.



Maximum allowable racking load for stapled surface splines is 208 PLF; for nailed 2x wood splines it is 385 PLF.



Top and bottom plates, OSB splines, nails and sealant. Nailing pattern is as described above.

Top and bottom plates connect to foundation/roof assemblies. Hangers for trusses/joists can be nailed directly to panel skins.


The 2x spline is easily adaptable. Top and bottom plates can make a variety of angles.


Lumber splines are more durable (under racking load, etc). Durability of connections at top and bottom is compatible to that of stick-frame construction.






Solid lumber connection is unlikely to withstand exposure to fire. spline connections.



Only 7/8" less insulating foam occurs at panel-to-panel connections.

Acoustical performance equals that of 2x lumber.


Whole-wall R-value of 6-1/2" wall is R 23.3 with with surface splines and R 22.3 with a solid 2x6 spline.

Thermal performance equals that of 2x lumber.


Expanding sealant helps limit moisture infiltration. Panel Seal Tape can be used to add another layer of protection. Inert foam insulation is not affected by moisture.

Sealant on both sides of bottom plate helps obstruct water path. Panel Seal Tape recommended at all panel-to-roof connections.


Expanding sealant in central keyway helps limit air infiltration. Panel Seal Tape can be used to add another layer of protection. Inert foam insulation is not affected by moisture. Surface splines block direct path from interior to exterior.

Sealant on both sides of bottom plate helps block air. Panel Seal Tape recommended at all panel-to-roof connections.



OSB can be treated with borate. EPS is penetrable but not particularly attractive to pests.

Similar to traditional stick-frame construction.

Connections at top and bottom are less likely to fail than the


continuedPrecision Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Foam is routed to fit splines and foam keyway. Splines cut to length.

Foam is routed to accommodate top/bottom plates.



Surface splines, expanding foam sealant, nails/fasteners. Plates, hangers (if needed), sealant, nails/fasteners.



Occassionally OSB panel edges can get damaged during shipping - makes installation more difficult, not impossible. Panels and connectors must be kept dry.

None


Splintered edges may be OK but broken surface splines need to be replaced - easy to cut more on-site.

If damaged, plates are easily replaced onsite and foam can be hot-scooped out to accommodate connections.


Set panels over bottom plate and adhesive and nail off. Apply foam to spline, pound spline into edge of panel, set next panel, foam and fasten to spline.



Hammer, foam sealant, nails, long screws, washers. Hammer, foam sealant, nails, long screws, washers, Panel Seal Tape.


Low Low



Panels can be modified and new connection points added but cutting panels and molding foam can be messy. New splines can easily be created on-site.

Yes



Product should interface with any other wood SIP system or wood framed construction.

Use of 2x top and bottom plates is consistent with other SIP panels and traditional stick framing.


Surface splines allow utilities to run continuously through the center of the panels.

Plates can be drilled out to accommodate utilities.



Very easy, no need to find studs and surface is very even. Same as stick framing.



Very easy, no need to find studs and surface is very even. Same as stick framing.



SIPs can be modified or removed after they are installed by cutting the panels, but sealants and frequent nails/fasteners will make getting panels apart intact difficult.

Accessible except for sealant.


Murus Company - Wood SIP Panels General Information

Distributor Name Murus Company Murus Company Description Wood SIP. Panels available as polyurethane (PUR) panel with

unique tongue and groove edge profile and patented Cam-Lock connectors. Also available is the expanded polystyrene (EPS) panel. Both panel types are available in various thicknesses, lengths and skin configurations. Both panels are sheathed with OSB.


Closed wall, wood SIP Closed wall, wood SIP


Non-uniform connection made with Cam-Locks. Non-uniform connection made with top and bottom plates and nails/screws.



Proprietary Cam-Lock, 6-7-8-9" galv. Ring shank or Ardox nails, or panel screws at corners

OSB panels slip over a treated 2x plate, are glued, sealed (with sealant) and nailed


Cam-Lock unit is approximately 6" tall and is imbedded into the panel approximately 4". The "tongue" of the cam is about 1/2" wide and 1/4" thick.

8d nails 6" o.c.


Vertical tolerance is as much as a half inch; horizontal is a couple of sixteenths (1/8").

Latitude can be taken up with the setting of the panels, therefore it is minimized, but the connection can adapt to site variables.


24" intervals, beginning 12" from top or bottom of panel. At corners, screw or nail 8" o.c.

Continuous, every 6" o.c.

Panels are precut and routed to accommodate plates in the factory


Panel connected over bottom plate

Cam-lock and special wrench

Panel-to-roof connection via angled top plate


continuedMurus Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Conforms to ICC and BOCA. Detailed tests performed for adhesion, cyclical aging, wind loads, and racking. Racking is the only test that specifically tests connections.

Conforms to ICC and BOCA. Detailed tests performed for adhesion, cyclical aging, wind loads, and racking. Racking is the only test that specifically tests connections.


Racking test results, sheetrock screws 8" o.c. Full Panel assemblies 430 lbs, 53.75 plf Panel w/ Door opening 400 lbs, 50 plf Panel w/ Window opening 430 lbs, 53.75 plf Compare camlocks to 2x4 (or 2x6) wood splines showed Cam-Locks only 10% weaker.

Racking test results, sheetrock screws 8" o.c. Full Panel assemblies 430 lbs, 53.75 plf Panel w/ Door opening 400 lbs, 50 plf Panel w/ Window opening 430 lbs, 53.75 plf Compare Cam-Locks to 2x4 (or 2x6) wood splines showed cam locks only 10% weaker.


Cam-Locks 2 at every panel joint 6" o.c.


Cam-Locks cannot accommodate irregular joins. Substitute 2x or other splines.

Yes


Cam-Locks are durable ABS plastic. OSB is much more subject to weakening under cyclical aging - ice, heat, steam.

Durable mechnical fasteners


Plastic potentially melts but is protected in the wall. Equivalent to traditional stick framing.



When the connection fails, the interior panel is exposed to the fire and produced noxious gas when burned.



Expect little or no change in sound transmission at connection. Sound transmission equivalent to that of dimensional lumber.


Plastic surrounded by foam. After locking, foam up the Cam-Lock through a small access hold.

Thermal bridging as with lumber.


Adhesive applied as panels are joined, then foam sprayed in through small holes after connection is complete helps keep water and moisture out. Plastic not susceptible to water.

Adhesive helps seal, and blocking increases travel distance water would have to travel to inner building.


Limited air infiltration thanks to good installation details and foam added to connection cavity after connections are made.

Limited air infiltration thanks to good installation details (bottom plate causes increase travel and caulking fills any voids).



Susceptible to any pests that destroy wood but OSB can be treated with borate. EPS is not attractive to pests.

Sealant helps keep pests out, but wood is susceptible to pests that destroy wood.


continuedMurus Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Cam-Locks are factory-installed during the foam expansion process. Foam sealant is added onsite.

The recess for the top and bottom plates are factory fabricated.



If a non-Cam-Lock connection is used, it is installed onsite -typically surface splines, or 2x dimensional corner connectors.

Slip panel over the bottom plate and nail onsite.



Plastic wrapped for moisture protection. OSB edges can get damaged and slow but not prevent installation.

Plastic wrapped for moisture protection. OSB edges can get damaged and slow but not prevent installation.


Murus reports that all Cam-Locks are not really necessary once top and bottom plates are in place; they report that you only need one or two working cam-locks for sound construction.

Good: bottom plate is easy to install, panel to panel connections are easy some edges may be worn and impede installation.


Panel set over plate, glue and foam applied within the recess. The next panel is set and builder uses a special key to engage the Cam-Locks. Foam squirted into Cam-Locks to finish.

Caulk and adhesive is applied to the bottom plate, and a panel is set on top of the plate. Nailed 12" o.c. around the perimeter of the panel. Top plates overlap panels.


Hammer, cam-lock wrench, nails, caulk or construction adhesive, foam insulation.

Hammer, chaulk, glue, nails.


Easy to set and lock into place; relatively low skill. Easy to set and fasten into place; relatively low skill.



Cam-Locks cannot be added in the field but panels are modifiable and substitutions (i.e., surface splines) can be used. Cam-Locks can be sliced through with a circular saw.

Panels can be modified in the field with a panel router and 16" circular saw.



Easy to tie other system into SIPs, similar to wood frame construction.



Plumbing and electrical cannot run through the Cam-Locks, but the locks are only about 6" high and spaced 24" o.c. leaving room for chases. One chase per panel is standard.

Yes, in some cases plumbing and electrical can make cuts into the bottom plate.



Smooth surface, no need to search for studs. Smooth surface, no need to search for studs.



Smooth surface, no need to search for studs. Smooth surface, no need to search for studs.



SIPs can be modified post-installation by cutting and the Cam-Locks themselves are reversible, but foam/adhesive impedes separation.

Difficult to actually disassemble the panel so it remains intact. Construction adhesive sealing panels to top and bottom plates complicates disassembly.


Agriboard - Wood SIP Panels General Information

Distributor Name Agriboard Agriboard Description Wood/Straw SIP. A panel system with a core made of

compressed agricultural fibers (wheat, rice, straw) and an OSB skin. The fiber board incorporates a natural mineral to resist termites, carpenter ants, and other pests. The board provides up to a 2.5-hour fire protection.


Closed wall


Panel-to-panel connections are the same as the panel-to-foundation or panel-to-ceiling connections. The panels are routed to accommodate a 2x2" "key" (track or plate) made of OSB.



Mechanical fasteners and OSB keys and sealant. Same as panel-to-panel connection.


Varies from connection type to connection type. Same as panel-to-panel connection.


1/8" Same as panel-to-panel connection.


Screws at 12" o.c. Same as panel-to-panel connection.

Agrifiber material Panels stacked in plant with formed keyways

Panel samples


Agriboard continued

Detail applies to both horizontal and vertical connections


Agriboard continued




International Building Code, International Residential Code, Florida Building Code.

International Building Code, International Residential Code, Florida Building Code.


Structural strength of overall panel system is known. Structural strength of overall panel system is kown.


12" o.c. 12" o.c.


Panels can be easily adaptable to all angles. Panels can be easily adaptable to all angles.


Keys and panels are durable but OSB is subject to weakening under racking load over time.

Top and bottom plates are durable.


Connections hold up well under fire testing. Connections hold up well under fire testing.



Connections fire resistance comparable to that of whole panel resistance.

Connections fire resistance comparable to that of whole panel resistance.



Wall filled with agrifiber insulation. Test results available. Wall filled with agrifiber insulation. Test results available.


Same as whole-panel insulation values. Same as whole-panel insulation values.


Relies on finishes for moisture and water resistance. Borate helps resist mold.

Relies on finishes for moisture and water resistance. Borate helps resist mold.


Sealant is used to fill voids. Bottom plate causes increase travel and caulking fills voids.



Borate used to provide insect barrier. Borate used to provide insect barrier.


Agriboard continued




Some panels are manufactured with the spline installed, or it is shipped to be installed at the job site.

Panel and connectors are shipped to site together.



Adhesive, nails. Adhesive, nails, key bolted to foundation.



Connections are packaged and sent with panels in shipment. Connections are packaged and sent with panels in shipment.


Installation is possible. Replacement keys can be made on-site. Installation is possible.


Panels set over bottom key, then adhesive is applied to vertical key, placed in panel keyway, adjacent panel is placed and both are nailed off on both sides of the seam.

Bottom key is bolted to foundation, and bead of adhesive is applied to its top before panels are placed over it and nailed off.


Hammer, chaulk, glue, nails. Hammer, chaulk, glue, nails.


Low Low










Four standard chases are cut during the manufacturing process. Four standard chases are cut during the manufacturing process.



It is actually easier to install drywall to the panel as compared to stick-built (connection is hidden in the panel).

It is actually easier to install drywall to the panel as compared to stick-built (connection is hidden in the panel).



The connection system does not hinder installation of exterior finishes. It works well with a variety of finishes.

The connection system does not hinder installation of exterior finishes. It works well with a variety of finishes.



Connection is not easily accessed after assembly. Connection is not easily accessed after assembly.


Bensonwood - Wood Open Wall Panels General Information

Distributor Name Bensonwood Panels Bensonwood Panels Description Wood. The OSB panel has a 16" o.c. stud framing. Features a

unique larger wiring chase, and manufacturer-installed boxes and conduits. These panels are custom-made and can be structural or not. Often used in conjunction with timber framing, where timbers bear the load rather than the panels.


Work with several types of panels but this research focuses on a closed-wall panel that uses OSB sandwiching 2x studs with blown cellulose insulation.


Panels have a 2x tongue-and-groove connection with gaskets for sealing, all connected with nails like conventional framing.

Panels have 2x top and bottom plates, nailed connections.



Nails and lumber similar to stick framing; Trelleborg gaskets (EPDM) for gaps tight to 1/2"; combination of chinking rod and PUR foam for 1/2" to 1" gaps.

Trelleborg gasket ST87 and construction adhesive (all tight joints), ringshank nails.


2 @ 1/2" and 3/4" dia. spaced 2 "


Good tolerances due to air sealing gaskets and foam. Similar to conventional wood framing.


every 6" o.c. Every 4" o.c.

Bensonwood Panels

2 @ 1/2" dia. spaces 2"


continuedBensonwood

Panels with 2x lumber tongue-and-groove edge

"Groove" portion of tongue-and-groove connection

Cutout for wire chase at panel's base. Receives baseboard cap later.

Gasket for better sealing at connections


continuedBensonwood Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



BWC National Building Code


Unknown Unknown


Nails, tongue and groove joints. Nails, headlocks.


Many angles possible. Yes


Comparable to wood framing. Comparable to wood framing.








No different than wood-framed construction; not tested, minimal airborne sound transmission.

Not tested, minimal airborne sound transmission.


Performs well due to gaskets and sealing, not superior. Performs well, not superior.


Performs well; gaskets make better connection than wood-frame construction.

Sealing and gaskets contribute to good water resistance.


Performs very well: gaskets make better connection than wood-frame construction.

Performs very well: gaskets make better connection than wood-frame construction.



Same susceptibility as wood-frame construction. Same susceptibility as wood-frame construction.


continuedBensonwood Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Gaskets applied in factory and fastened on site. Gaskets at top plate factory installed fasteners site installed.



Fasteners, gaskets, chinking rod, and sealant applied in field. Adhesive, gasket, and fastener applied on site(bottom plate).



Gaskets fastened with staples. Other components need no special protection.

Gaskets fastened with staples. Other components need no special protection.


Yes Yes


Panels are prepped on ground (fasteners) Trelleborg gaskets are stapled to panel; combination gets installed later.

Panels are set in place; fasterners driven after.


Screw gun, hammer, hammer stapler. Screw gun, hammer, hammer stapler.


Low Low



Field changes will likely need to be framed and connected like typical wood-frame construction.

The top and bottom plates are easily adjustable.



Yes, no different than wood framing. Yes


Yes - a recess at the panel's base allows for utilities, and can be covered with baseboard later on.

No



Additional sheathing makes hanging drywall easier; no need to hit studs.

Comparable to wood framing.






Yes Yes


Wausau Homes - Wood Open-Wall Panels General Information

Distributor Name Wausau Homes Wausau Homes Description Wood Open Wall. Interior wall panels are open frame.Exterior

wall panels are open-frame on the inside surface. The outside surface has plywood, OSB, or foam sheathing and house-wrap plant applied, windows and entry doors plant installed with weatherization flashing. Wausau makes floor panels and roof trusses for Whole House design.


Open Wall


Connections made using nails and fasteners, identical to wood stick-frame construction.



Dimensional lumber, nails, sheathing. Dimensional lumber, nails, hangers.


Dimensional lumber studs, overlapping top and bottom plates, and overlapping sheathing are used with nails to attach the panels to each other.

Dimensional lumber top plates connect panels to each other and to floor. Hangers connect top plate to roof/joists.


Connections have a great deal of latitude, limited primarily by the difficulty of installing finish systems over uneven panelized construction.



Nailing patterns vary depending on design loads: 8" - 32" o.c., 1 nail per joist, etc. Typical detail is 3 16D nails where top plates overlap adjoining panels. 2 16D nails 32" o.c. at corners.

Wall to floor and top plate: 2 16D nails ever 16" o.c. Truss and joist anchors w/ hanger nails for second story floor and roof.

Panels with pre-installed components Panels set and roof truss in place


continuedWausau Homes

Panels installed with plates and ladder blocking

Bottom plate spliced connection in factory

Panel-to-panel connection in field with double stud

Top plates tied to roof trusses


continuedWausau Homes Performance characteristics Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Panel connections meet same requirements as a site-built home.



N/A Same as panel-to-panel.


Top plates overlap and are nailed. At corners, sheathing overlaps and is nailed. Adjoining studs are nailed together.

Bottom plate is nailed to floor. Top plates connect adjoining panels, and hangers are used to connect joists.


Yes, this type of panel is highly flexible. Same as panel-to-panel.


Durability comparable to traditional wood framing. Factory precision contributes to long-lasting construction.



Wood plates and studs used to connect panels are susceptible to fire and must be covered with drywall or other finishing material to meet fire codes.




Connections are no more susceptible to fire than the whole wall. Same as panel-to-panel.



Acoustical performance equals that of dimensional lumber. Same as panel-to-panel.


Thermal performance equals that of dimensional lumber. Same as panel-to-panel.


Wood is typically susceptible to moisture, and is protected by exterior and interior finish systems. At customer's (builder's) option, the manufacturer will add waterproofing products.



At customer's (builder's) option, the manufacturer will add airsealing measures (foam, etc).




Wood is typically susceptible to insects and vermin, and is protected by exterior and interior cladding. At customer's (builder's) option, the manufacturer will add Borate treatment.



continuedWausau Homes Connection Interface Panel-to-Panel Connections Panel-to-Top/Bottom Plate Connections



Panels are complete with top and bottom plates, ladder blocking, and overhanging top plates and sheathing (at corners) for panel-to-panel connections.

Plates are factory installed.



All nailing is performed on-site. All nailing and hanger installation is performed on-site.



Panels are primarily shipped vertically and are carefully loaded to protect the pre-installed doors and windows. Sheathing overhangs are probably most vulnerable.

Panels are primarily shipped vertically and are carefully loaded to protect the pre-installed doors and windows. Sheathing overhangs are probably most vulnerable.


Problems can be fixed on-site with traditional wood-frame building materials.

Problems can be fixed on-site with traditional wood-frame building materials.


Builder sets panels with equipment or by hand, beginning in a corner and nailing panels into place. Bracing is used to support the panels during installation.

Builder sets panels with equipment or by hand, beginning in a corner and nailing panels into place. Bracing is used to support the panels during installation.


Nailgun, hammer. Nailgun, hammer.


Less skill than traditional wood framing. Less skill than traditional wood framing.



Highly flexible panel connection system accommodates changes eaily using traditional building materials. Factory-installed windows, doors, and exterior cladding may limit changeability.

Highly flexible panel connection system accommodates changes eaily using traditional building materials. Factory-installed windows, doors, and exterior cladding may limit changeability.



These panels can be joined to other panelized systems, for instance SIPs, using a dimensional lumber spline to transition between panels.

These panels can be joined to other panelized systems, for instance SIPs, using a dimensional lumber spline to transition between panels.


Compatibility is identical to that of traditional stick framing.



Similar to stick framing, although factory quality control tends to make for straighter walls and easier finish application, including areas over connections. When installed, connections perform the same as the rest of the panel.

Similar to stick framing, although factory quality control tends to make for straighter walls and easier finish application, including areas over connections. When installed, connections perform the same as the rest of the panel.



Exterior finishes are factory-installed except for trim, which can be easily applied over the panel connections at corners and joists.

Exterior finishes are factory-installed except for trim, which can be easily applied over the panel connections at corners and joists.



Access is identical to that of traditional stick framing. Nails can be removed.

Access is identical to that of traditional stick framing. Nails can be removed.

Compatibility is identical to that of traditional stick framing.


Strong-Wall Shearwall - Wood Open-Wall Panels General Information

Distributor Name Simpson Strong-Wall Shearwall Simpson Strong-Wall Shearwall Description Simpson makes a variety of fasteners and shearwall products.

This research focuses on the wood Strong-Wall Shearwall.


Wood open-wall panel reinforced with additional framing and metal channels. Typically used in conjunction with Simpson tie-downs for maximum shear resistance for high design loads.


The panel-to-panel connections and the panel to top/bottom plate connection differ. Shearwall panels are typically set next to other wood framing or wood open wall panels, mainly in garage portals. Shearwall panels connect to adjacent studs (posts) or panels using nails and rectangular straps or nailing plates.

The panel-to-panel connections and the panel to top/bottom plate connection differ. Connect to roof or framing at the top with nailed straps. Connect to foundation anchor bolts and foundation bolts, secured with nuts.



Straps, nails, screws. Hold-down anchor bolts, straps, foundation bolts.


Specific fastener used vary widely based on building design and conditions. Simpson makes a wide variety of fasteners.

Two SSTB28 anchor bolts (SSTB34 for 2 pour applications) and minimum 5/8" x 12" foundation bolts into template a maximum of 1" above template, secured with nuts.


Precision is important for safety. Templates accompnay panels and fasteners to ensure precise installation.

Precision is important for safety. Templates accompnay panels and fasteners to ensure precise installation.


Depends upon loading, but typically two straps plus nailing. Typically 2 straps at top and 2 bolts to anchor bottom.

Strong-Wall Shearwall panels stacked for delivery

Shearwall panel installed


Strong-Wall continued

Typical garage portal application Panel in place at corner

Metal edges add strength to panel

Hold-downs and foundation bolts embedded in concrete






Conforms to the IBC and the UBC, California Building Code and various other building codes, ICC, State of Florida.

Conforms to the IBC and the UBC, California Building Code and various other building codes, ICC, State of Florida.


All Simpson connectors are engineered. Strengths are given for the wall as a whole, including the specified connectors.

All Simpson connectors are engineered. Strengths are given for the wall as a whole, including the specified connectors.


Depends upon loading, but typically two straps plus nailing. Typically 2 straps at top and 2 bolts to anchor bottom.


While connections are not limited, shearwalls are typically installed square to the building for greatest strength.

While connections are not limited, shearwalls are typically installed square to the building for greatest strength.


The shearwall was creating to withstands heaving loads without weakening.

The shearwall was creating to withstands heaving loads without weakening.


Unknown Unknown



Unknown Unknown



Where additional studs or posts are used, acoustical transmission will increase.

Anchor bolts and takeup devices contribute to sound transmission, as do additional top and bottom plates.


Where additional studs or posts are used, thermal bridging will increase.

Anchor bolts and takeup devices contribute to energy transmission, as do additional top and bottom plates.


All fasteners are galvanized to resist rust. All fasteners are galvanized to resist rust.


No special resistance. No special resistance.



No special resistance. No special resistance.






Panels and connectors are shipped to the site together. Panel and connectors are shipped to the site together.



All connectors are field-installed. The anchors must be set in concrete prior to installation.



Panel and connectors are packaged for protection during shipment.

Panel and connectors are packaged for protection during shipment.


This wall cannot be installed with damaged connectors. This wall cannot be installed with damaged connectors.


Simpson provides a fool proof system for installation by including installation instructions attached to the wall during shipment. They have provided the builder with a product that doesn't require a high skill level for installation.

Simpson provides a fool proof system for installation by including installation instructions attached to the wall during shipment. They have provided the builder with a product that doesn't require a high skill level for installation.


No special tools required. No special tools required.


Low/medium skill level required. Low/medium skill level required.



This wall system was not created for change after installation. This wall system was not created for change after installation.



This wall system is compatible with other wall systems including SIPs and wood open wall, as well as conventional wood framing.

This wall system is compatible with other wall systems.


It offers multiple prefabricated holes for electrical and wiring. House subsystems are accomodated including several spaces for wiring or different types.



The system is set up for the future installation of interior and exterior finishes.








The strap tie connections are easy to access. The connections are easy to access, except the anchors set in concrete.


APPENDIX B PANEL MANUFACTURER MATRIX

This matrix includes the 12 panel systems studied, which represent the state-of-practice of connections being used today. The matrix categorizes the 12 systems by 4 of the most popular panel types used by the U.S. homebuilding industry: concrete panels, metal panels, wood structural insulated panels (SIPs), and wood open-wall panels. The 12 systems are distributed among these 4 panel systems types as follows: concrete panels (2 systems); metal panels (3 systems); wood SIPs (4 systems); wood open-wall panels (3 systems).


PATH 23 PANEL CONNECTIONS DESIGN STUDY PANEL MANUFACTURER MATRIXConcrete Panels

OldCastle, NY A concrete panel with carbon fibers (TEchFab) and rebar for support. The panel is backed with expanded polystyrene. For residential interior and exterior walls and floors. Vertical connections use a NMB Splice Sleeve System. Most horizontal panel to panel connections are made through embedding weld plates into the panel during the casting phase; then making a welded connection during installation.

Dukane Precast Inc., IL Concrete Sandwich. A double wall of precast concrete, with steel trusses girders connecting two sides. The panel is insulated with various types of insulation. For exterior residential and commercial walls and floors. Panels are grouted together inside and caulked outside. Floor and ceiling are cemented in.

Metal Panels Acsys Panel System, ThermaSteel, VA

Steel Frame/Foam. A panel with a core of EPS framed with 24-gauge, G-90 galvanizing steel studs, typically finished on interior with appropriate gypsum composite although any type of cladding may be field applied to the interior and exterior. For residential and commercial interior and exterior walls. Connected with shiplap joints and self-tapping tech screws. Preferred method: metal tracks for top and bottom plate.

Acsys Inc., ID Steel Frame/Foam. An insulated steel-core wall panel made of 16-20 gauge galvanized corrugated structural core welded to a top and bottom 18 gauge galvanized steel track. Steel tracks are embedded in expanded polystyrene skin using a specialized molding process. For residential and commercial exterior walls. The product is supplied with mounting track, fasteners, and corner connectors.

SIPbLOC, Metals USA Building Products, TX

SIP- Steel/Metal Sheet/Foam Core. The panel is made of expanded polystyrene (EPS) foam insulation sandwiched between two structural skins of steel or aluminum. The unique feature of this system is the mechanism used to lock the panels together. For residential and commercial exterior walls and roofs. Connected via Integrated snap-and-lock system with sealant.

Wood SIPs

Insulspan Wood SIP. Expanded Polystyrene (EPS) core bonded between two outer layers of Oriented Strand Board (OSB). For residential and commercial walls, roofs, and floors. Panels sit on 2x plating, which in turn sits on a treated sill plate anchored to foundation. Connect panels w/ double OSB surface splines (most common), nails or screws, and sealant. Other spline types can be used including 2x4 lumber splines.

Precision Panel Wood SIP. Expanded Polystyrene (EPS) core bonded between two outer layers of Oriented Strand Board (OSB). For residential and commercial walls, roofs, and floors. Panels sit on 2x plating, which in turn sits on a treated sill plate anchored to foundation. Connect panels w/ either 2x4 lumber splines, OSB surface splines, or insulated “superspline” resembling a mini-panel. Connections also use sealant and nails or screws.

Murus, PA Wood SIP. Polyurethane (PUR) or EPS insulation core w/ OSB sheathing. Unique tongue and groove edge profile and patented cam-lock connectors with Urethane panels. For residential and commercial exterior walls, roofs, floors. Once one or two of the cam locks are engaged, the panel is supported correctly in place and is ready to be secured to the framing members. Sealant is added to the panel-to-panel connection. Top and bottom plates provide majority of connection strength.

Agriboard, Raytheon Wood/Straw SIP. A panel system with a core made of compressed agricultural fibers (wheat, rice, straw) and an OSB skin. The fiber board incorporates a natural Engineers & Constuctors, mineral to resist termites, carpenter ants and other pests. The board provides up to a 2-hour fire resistance. For residential exterior walls, roofs, floors. Connected TX using 2x2 wood ‘keys’ fitted into keyways along panel edges. Connections completed with sealant and nails. Wood Framed Panels

Bensonwood Open-Wall Panels, NH

Wood. The OSB panel has a 16" o.c. I-flange framing and is insulated with urethane. Features a unique larger wiring chase, and manufacturer-installed boxes and conduits. These panels are custom-made and can be structural or not. Often used in conjunction with timber framing, where timbers bear the load rather than the panels. For residential exterior walls. Connected with shiplap joints, gaskets, and foam.

Wasau Homes, WI Wood Open Wall. Interior wall panels are open frame, while exterior wall panels are open frame on the inside surface. The outside surface has plywood, OSB or foam sheathing & house-wrap plant applied, windows & entry doors plant installed with weatherization flashing. Panels are for residential and light commercial floors, walls, and roofs. Connected with nails, spikes, plates, hangers and other conventional mechanical fasteners. Meets requirements for high wind load design and foundation anchorage.

Strong-Wall Shearwall, Simpson Strong Tie, CA

Wood Open Wall. This panel is an open wall prefabricated wood shear wall. The panel achieves high design loads proven by cyclic testing. For residential exterior walls and garages, when the area requires high load and/or shear load bearing capability. Templates are used to place the required holdown and mudsill anchor bolts accurately in the foundation. The wall panels cover the anchor bolts, followed by top and bottom plate attachment.

Panlized Wall Systems: Making the Connections 69

disclaimer 3 executive summary 4 context of research 4 research

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